JP2012140554A - Method for producing aliphatic polyester - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for continuously producing an aliphatic polyester, which dispenses with an excessive vacuum facility, and can attain a high rate of melt-polycondensation reaction while reducing by-production of THF or volatilization of a low-molecular weight component in the melt-polycondensation step.SOLUTION: The method for producing an aliphatic polyester comprises: an esterification step of performing esterification reaction in an esterification reaction tank by use of an aliphatic dicarboxylic component and 1,4-butanediol as raw materials to obtain an esterified reaction product; and a polycondensation step of continuously subjecting the esterified reaction product to melt-polycondensation reaction in a plurality of stages of polycondensation reaction tanks to obtain the aliphatic polyester. The ratio (R) of terminal acid value to total terminal group amount of a molten polymer in the esterification reaction tank and the polycondensation reaction tank is controlled to ≥0.40 and ≤0.80, and Pmin is ≥0.20 kPa, wherein Pmin is the pressure in the polycondensation reaction tank with the lowest pressure of reaction pressures in the polycondensation step.

Description

  The present invention relates to a method for producing an aliphatic polyester. More specifically, the present invention relates to an efficient and stable continuous production method of a high molecular weight aliphatic polyester having a small amount of by-products and volatile components.

  In recent years, awareness of environmental issues such as depletion of fossil fuels and an increase in carbon dioxide in the atmosphere has increased, and in the plastics industry, countermeasures for environmental issues that take into consideration the life cycle from product manufacture to disposal have become urgent. ing.

  Under these circumstances, aliphatic polyesters obtained from aliphatic dicarboxylic acids and aliphatic diols have attracted attention as environmentally friendly plastics. Aliphatic polyesters can be made from raw aliphatic dicarboxylic acids (for example, succinic acid and adipic acid) from plant-derived glucose by fermentation, and aliphatic diols (for example, ethylene glycol, propanediol, butanediol). ) Can also be produced from plant-derived materials, so that resource saving of fossil fuels can be achieved. At the same time, the growth of plants absorbs carbon dioxide in the atmosphere, which can greatly contribute to the reduction of carbon dioxide emissions. Furthermore, it is also known to exhibit excellent biodegradability, and it can be said that the aliphatic polyester is a triple-friendly plastic.

  The aliphatic polyester is usually obtained by subjecting an aliphatic dicarboxylic acid and an aliphatic diol to an esterification reaction and then performing a melt polycondensation reaction. These reactions are usually performed by a batch method, a continuous method, or a combination of a batch method and a continuous method. Among these, when mass-producing industrially, the continuous method is advantageous in terms of productivity, quality stability, economy, etc., and those that are mass-produced such as polyethylene terephthalate and polybutylene terephthalate are based on the continuous method. There are overwhelmingly many things.

  The continuous production method of aliphatic polyester is disclosed in Patent Document 1. This document discloses that the molar ratio of the aliphatic diol component to the aliphatic dicarboxylic acid component in the esterification step is within a specified range. However, in the specifically disclosed technique, an aliphatic polyester is used. In order to increase the molecular weight to a predetermined level, it is necessary to carry out a polycondensation reaction under a high vacuum, and when the aliphatic diol is 1,4-butanediol, a cyclization reaction of a terminal group in the polycondensation reaction step Due to the large amount of by-product of tetrahydrofuran (sometimes referred to as THF), excessive vacuum equipment was required to achieve a high degree of vacuum, which was industrially disadvantageous. As a further problem, since a large amount of low-molecular-weight components such as cyclic dimers and other oligomers are generated, clogging with condensers often occurs, and aliphatic polyesters can be produced continuously and stably over a long period of time. Was not necessarily enough.

  In addition, Patent Document 2 discloses that the reaction temperature of esterification and melt polycondensation is not higher than a specified temperature for the purpose of suppressing the decomposition reaction during the reaction. In the technology, the polymerization reaction rate is not always sufficient, so it is necessary to react the polycondensation step under high vacuum. As a result, many volatile components of low molecular weight components are generated, and this is not always satisfactory. It wasn't possible.

  Patent Document 3 discloses that the amount of terminal carboxyl groups relative to the total amount of terminal groups of the polycondensation reaction product supplied to the final polycondensation reaction tank of the polycondensation step for the purpose of reducing the amount of cyclic oligomer in the aliphatic polyester. Although a method for producing an aliphatic polyester having a ratio (R) of 0.15 or more is disclosed, although the amount of by-product THF in the final stage can be reduced by the specifically disclosed technique, Since the amount of THF by-product in the polycondensation reaction tank other than the final stage where the reaction was remarkable was large, it was not always satisfactory.

  Further, Patent Document 4 discloses a method for producing an aliphatic polyester under a reaction pressure of more than 1.0 mmHg to 5.0 mmHg, but the specifically disclosed technique has a slow polymerization reaction rate. There is also a problem that the predetermined molecular weight is not reached.

JP 2009-155556 A JP 2006-265503 A JP 2010-209268 A Japanese Patent No. 2968466

  In view of the above problems, the present invention does not require an excessive vacuum facility, and has a high melt polycondensation reaction rate, a by-product of THF in the polycondensation step, and low volatilization of low molecular weight components, an aliphatic group. It aims at providing the continuous manufacturing method of polyester.

  As a result of studying the above problems, the present inventors have determined that the ester group quality in the esterification reaction tank and the polycondensation reaction tank is a specific ratio in the continuous production of aliphatic polyester. By optimizing conditions such as temperature, pressure, residence time, molar ratio of 1,4-butanediol to aliphatic dicarboxylic acid component in the conversion step and polycondensation step, without requiring excessive vacuum equipment The present inventors have found that an aliphatic polyester can be efficiently produced by reducing the volatilization of THF by-product and low molecular weight components in the polycondensation step, resulting in a high rate of melt polycondensation reaction, leading to the present invention. .

  That is, the method for producing an aliphatic polyester according to the present invention includes an esterification step in which an esterification reaction product is obtained by performing an esterification reaction in an esterification reaction vessel using an aliphatic dicarboxylic acid component and 1,4-butanediol as raw materials. And a polycondensation step of continuously performing a melt polycondensation reaction of the esterification reaction product in a multistage polycondensation reaction tank to obtain an aliphatic polyester. The ratio (R) of the terminal acid value to the total terminal group amount of the molten polymer in the tank and the polycondensation reaction tank is controlled to 0.40 or more and 0.80 or less, and the reaction pressure in the polycondensation step is the most When the pressure of the low-pressure polycondensation reaction tank is Pmin, Pmin ≧ 0.20 kPa.

  Moreover, in this invention, it is preferable that the molar ratio of the diol component with respect to the dicarboxylic acid component supplied to an esterification reaction tank is 0.8 or more and 1.3 or less.

  In the present invention, Pmin is preferably Pmin ≧ 0.25 kPa.

  In the present invention, when the temperature of the polycondensation reaction tank having the highest temperature among the reaction temperatures in the polycondensation step is Tmax, it is preferable that Tmax ≦ 260 ° C.

  In the present invention, 1,4-butanediol is added to at least one polycondensation reaction tank in the polycondensation step to control the ratio (R) of the terminal acid number to the total terminal group amount of the molten polymer. Is preferred.

  In the present invention, a titanium compound is preferably used as the polycondensation reaction catalyst.

  ADVANTAGE OF THE INVENTION According to this invention, the melt polycondensation reaction rate is large, and the continuous manufacturing method of the aliphatic polyester by which the THF by-product amount in the polycondensation process and the volatilization amount of the low molecular weight component was reduced can be provided. Moreover, according to the method of the present invention, since aliphatic polyester can be continuously produced efficiently and stably over a long period of time without requiring excessive vacuum equipment, it is possible to provide an aliphatic polyester with stable quality. It can contribute to the expansion of the use of polyester derived from biomass.

It is a systematic diagram which shows an example of the esterification process in this invention. It is a systematic diagram which shows an example of the polycondensation process in this invention.

  Hereinafter, embodiments of the method for producing an aliphatic polyester of the present invention will be described in detail.

The present invention relates to a method for continuously producing an aliphatic polyester, in which a diol component containing an aliphatic dicarboxylic acid component and 1,4-butanediol is used as a raw material, and a polyester is obtained through an esterification reaction and a melt polycondensation reaction. is there.
In the present invention, the “aliphatic dicarboxylic acid component” means that 85 mol% or more of the total dicarboxylic acid component is an aliphatic dicarboxylic acid and a derivative thereof.
Hereinafter, the raw material of the aliphatic polyester and the production method of the present invention will be described in detail.

(1) Raw material of aliphatic polyester Specific examples of the aliphatic dicarboxylic acid contained in the aliphatic dicarboxylic acid component that is the raw material of aliphatic polyester include oxalic acid, malonic acid, succinic acid, glutaric acid, and adipine. Examples include acids, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecadicarboxylic acid, dodecadicarboxylic acid, dimer acid, hexahydrophthalic acid, hexahydroisophthalic acid, hexahydroterephthalic acid and the like. Among these aliphatic dicarboxylic acids, succinic acid, succinic anhydride, adipic acid and the like can be derived from plant raw materials. An acid anhydride may be used as the derivative of the aliphatic dicarboxylic acid, and specific examples thereof include succinic anhydride. These aliphatic dicarboxylic acids and derivatives thereof may be used alone or in combination of two or more. Among these, succinic acid, succinic anhydride, adipic acid, and sebacic acid are preferable, and succinic acid is particularly preferable from the viewpoint of physical properties of the obtained polyester.

  In addition to the aliphatic dicarboxylic acid and derivatives thereof, aromatic dicarboxylic acid and derivatives thereof may be used in combination. Specific examples of the aromatic dicarboxylic acid include terephthalic acid, isophthalic acid, naphthalenedicarboxylic acid, And diphenyldicarboxylic acid. Aromatic dicarboxylic acids and derivatives thereof may be used alone or in combination of two or more.

  In the present invention, succinic acid is preferably contained in an aliphatic dicarboxylic acid component in an amount of 50 mol% or more from the viewpoint of the melting point (heat resistance), biodegradability, and mechanical properties of the resulting aliphatic polyester, %, Preferably 90 mol% or more.

  In the present invention, 1,4-butanediol is used as the diol component which is another raw material of the aliphatic polyester, but other diol components other than 1,4-butanediol may be copolymerized.

  Specific examples of other diol components include ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,5-pentanediol, 1,6-hexanediol, and 1,7-heptane. Diol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, neopentyl glycol, diethylene glycol, polyethylene glycol, polypropylene glycol, polytetramethylene ether glycol and other aliphatic diols, 1,2- Cycloaliphatic diols such as cyclohexanediol, 1,4-cyclohexanediol, 1,2-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, xylylene glycol, 4,4′-dihydroxybiphenyl, 2,2-bis ( 4-hydroxypheny E) aromatic diols such as propane and bis (4-hydroxyphenyl) sulfone, and diols derived from plant materials such as isosorbide, isomannide, isoidet, and erythritan.

1,4-butanediol, ethylene glycol, 1,3-propanediol and the like can also be derived from plant raw materials.
These diol components may be used alone or in combination of two or more.

  In the present invention, 1,4-butanediol is preferably contained in an amount of 50 mol% or more based on the total diol component from the viewpoint of the melting point (heat resistance), biodegradability, and mechanical properties of the resulting aliphatic polyester. , More preferably 70 mol% or more, and particularly preferably 90 mol% or more.

  In the present invention, the raw material of the aliphatic polyester may contain other components other than the aliphatic dicarboxylic acid component and the diol component. Examples of other copolymer components include lactic acid, glycolic acid, hydroxybutyric acid, hydroxycaproic acid, 2-hydroxy-3,3-dimethylbutyric acid, 2-hydroxy-3-methylbutyric acid, and 2-hydroxyisocaproic acid , Malic acid, citric acid, and oxycarboxylic acids such as esters, lactones, and oxycarboxylic acid polymers of these oxycarboxylic acids; unsaturated carboxylic acids such as maleic acid and fumaric acid; glycerin, trimethylolpropane, pentaerythritol, etc. A trifunctional or higher polyhydric alcohol; a trifunctional or higher polyhydric carboxylic acid such as propanetricarboxylic acid, pyromellitic acid, trimellitic acid, benzophenonetetracarboxylic acid and anhydrides thereof, or an anhydride thereof.

  In particular, a polyfunctional compound such as a trifunctional or higher functional oxycarboxylic acid, a trifunctional or higher polyhydric alcohol, a trifunctional or higher polyvalent carboxylic acid, and the like can be obtained by adding a small amount as a copolymerization component to obtain a highly viscous polyester. preferable. Among these, malic acid, citric acid, and fumaric acid are preferable, and malic acid is particularly preferably used.

  When these trifunctional or higher polyfunctional compounds are added to the raw material, the amount thereof is preferably 0.001 to 5 mol%, more preferably 0.05 to 5%, based on all dicarboxylic acid components in the raw material. 0.5 mol%. If the upper limit of this range is exceeded, gel (unmelted product) is likely to be generated, and if it is less than the lower limit, the effect of increasing the viscosity tends to be difficult to obtain.

(2) Catalyst In the production method of the present invention, a reaction catalyst can be added by an esterification reaction or a polycondensation reaction in order to accelerate the reaction. However, if an esterification reaction catalyst is present during the esterification reaction, water generated by the esterification reaction may cause the catalyst to produce insoluble precipitates in the reaction product, thereby impairing the transparency of the resulting polyester (ie, increasing haze). Yes, it may become a foreign object. In the esterification reaction, it is preferable not to use a reaction catalyst during the esterification reaction because a sufficient reaction rate can be obtained without an esterification reaction catalyst. When adding an esterification reaction catalyst, adding the catalyst to the gas phase part of the esterification reaction tank may increase haze, and the catalyst may be converted to a foreign substance. Therefore, it is preferable to add it to the reaction solution. .

  On the other hand, in the polycondensation reaction, it is difficult to proceed without a catalyst, and therefore a catalyst is preferably used. As the polycondensation reaction catalyst, a compound containing at least one of the metal elements of Groups 1 to 14 of the periodic table is generally used. Specific examples of the metal element include scandium, yttrium, samarium, titanium, zirconium, vanadium, chromium, molybdenum, tungsten, tin, antimony, cerium, germanium, zinc, cobalt, manganese, iron, aluminum, magnesium, and calcium. , Strontium, sodium and potassium. Among them, scandium, yttrium, titanium, zirconium, vanadium, molybdenum, tungsten, zinc, iron, and germanium are preferable, and titanium, zirconium, tungsten, iron, and germanium are particularly preferable. Furthermore, in order to reduce the polyester terminal density | concentration which affects the thermal stability of the aliphatic polyester obtained, the metal element of the periodic table 3-6 group which shows Lewis acidity among the said metal elements is preferable. Specifically, scandium, titanium, zirconium, vanadium, molybdenum, and tungsten are preferable. Of these, titanium and zirconium are preferable because of easy availability, and titanium is particularly preferable from the viewpoint of reaction activity.

  In the present invention, as a catalyst, a compound containing an organic group such as a carboxylate salt, an alkoxy salt, an organic sulfonate salt, or a β-diketonate salt containing these metal elements, and further, an oxide or halide of the metal element described above. Inorganic compounds such as these and mixtures thereof are preferably used.

  The titanium compound as the catalyst is preferably a tetraalkyl titanate or a hydrolyzate thereof. Specifically, tetra-n-propyl titanate, tetraisopropyl titanate, tetra-n-butyl titanate, tetra-t-butyl titanate, tetra Examples include phenyl titanate, tetracyclohexyl titanate, tetrabenzyl titanate and mixed titanates thereof, and hydrolysates thereof. Also, titanium (oxy) acetylacetonate, titanium tetraacetylacetonate, titanium (diisopropoxide) acetylacetonate, titanium bis (ammonium lactate) dihydroxide, titanium bis (ethylacetoacetate) diisopropoxide, titanium (tri Ethanolaminate) isopropoxide, polyhydroxytitanium stearate, titanium lactate, titanium triethanolamate, butyl titanate dimer and the like are also preferably used. Moreover, the liquid substance obtained by mixing alcohol, an alkaline-earth metal compound, a phosphate ester compound, and a titanium compound is also used. Among these, tetra-n-propyl titanate, tetraisopropyl titanate and tetra-n-butyl titanate, titanium (oxy) acetylacetonate, titanium tetraacetylacetonate, titanium bis (ammonium lactate) dihydroxide, polyhydroxytitanium stearate Preferred is a liquid obtained by mixing rate, titanium lactate, butyl titanate dimer, and alcohol, alkaline earth metal compound, phosphate ester compound, and titanium compound. Tetra-n-butyl titanate, titanium (oxy) Acetyl acetonate, titanium tetraacetyl acetonate, polyhydroxy titanium stearate, titanium lactate, butyl titanate dimer, alcohol, alkaline earth metal compound, phosphate ester More preferred are liquids obtained by mixing tellurium compounds and titanium compounds, especially tetra-n-butyl titanate, polyhydroxytitanium stearate, titanium (oxy) acetylacetonate, titanium tetraacetylacetonate and alcohol. A liquid material obtained by mixing an alkaline earth metal compound, a phosphate ester compound, and a titanium compound is preferred.

  Specific examples of the zirconium compound include zirconium tetraacetate, zirconium acetylate hydroxide, zirconium tris (butoxy) stearate, zirconyl diacetate, zirconium oxalate, zirconyl oxalate, zirconium ammonium oxalate, and zirconium oxalate. Potassium, polyhydroxyzirconium stearate, zirconium ethoxide, zirconium tetra-n-propoxide, zirconium tetraisopropoxide, zirconium tetra-n-butoxide, zirconium tetra-t-butoxide, zirconium tributoxyacetylacetonate and mixtures thereof Is exemplified. Among these, zirconyl diacetate, zirconium tris (butoxy) stearate, zirconium tetraacetate, zirconium acetate acetate, zirconium ammonium oxalate, zirconium potassium oxalate, polyhydroxyzirconium stearate, zirconium tetra-n- Propoxide, zirconium tetraisopropoxide, zirconium tetra-n-butoxide, zirconium tetra-t-butoxide are preferred, zirconyl diacetate, zirconium tetraacetate, zirconium acetate acetate hydroxide, zirconium tris (butoxy) stearate, sulphur Zirconium ammonium acid, zirconium tetra-n-propoxide, zirconium tetra-n-butoxide are more preferred, It preferred because zirconium tris (butoxy) stearate is easily obtained polyester having a high degree of polymerization without colored.

  Specific examples of the germanium compound include inorganic germanium compounds such as germanium oxide and germanium chloride, and organic germanium compounds such as tetraalkoxygermanium. In view of price and availability, germanium oxide, tetraethoxygermanium, tetrabutoxygermanium, and the like are preferable, and germanium oxide is particularly preferable.

  Other metal-containing compounds include scandium carbonate, scandium acetate, scandium chloride, scandium compounds such as scandium acetylacetonate, yttrium carbonate, yttrium chloride, yttrium acetate, yttrium acetate such as yttrium acetylacetonate, vanadium chloride, and vanadium trichloride. Oxides, vanadium acetylacetonate, vanadium compounds such as vanadium acetylacetonate oxide, molybdenum compounds such as molybdenum chloride, molybdenum acetate, tungsten compounds such as tungsten chloride, tungsten acetate, tungstic acid, cerium chloride, samarium chloride, ytterbium chloride, etc. Examples include lanthanoid compounds.

  Further, when a known layered silicate described in “Clay Mineralogy” by Haruo Shiramizu, Asakura Shoten (1995) or the like is used alone or in combination with the above metal compound, the polycondensation reaction rate may be improved. For this reason, such a catalyst system is also preferably used.

  Specific examples of layered silicates include kaolins such as dickite, nacrite, kaolinite, anorokite, metahalloysite, halloysite, serpentine groups such as chrysotile, lizardite, antigolite, montmorillonite, zauconite, beidellite, Smectites such as nontronite, saponite, hectorite, stevensite, vermiculites such as vermiculite, mica, illite, sericite, mica such as sea green stone, attapulgite, sepiolite, palygorskite, bentonite, pyrophyllite, talc And chlorite group.

  In the present invention, the catalyst is preferably a compound that is liquid in the polycondensation reaction or dissolved in an ester low polymer or polyester because the polymerization rate is increased when the catalyst is melted or dissolved in the polycondensation reaction. In addition, the polycondensation reaction is preferably carried out without a solvent. Alternatively, a small amount of solvent may be used to dissolve the catalyst. Examples of the solvent for dissolving the catalyst include alcohols such as methanol, ethanol, isopropanol, and butanol, diols such as ethylene glycol, butanediol, and pentanediol, ethers such as diethyl ether and tetrahydrofuran, and nitriles such as acetonitrile. , Hydrocarbon compounds such as heptane and toluene, water and mixtures thereof. Among them, when an aliphatic diol that is a raw material main component of the aliphatic polyester to be produced, that is, 1,4-butanediol in the present invention, is used as a solvent for dissolving the catalyst, the polycondensation reaction is substantially carried out without a solvent. Since it can be performed, it is preferable. The solvent for dissolving the catalyst is used so that the catalyst concentration is usually 0.0001% by mass or more and 99% by mass or less.

  Further, the amount of catalyst added when using a metal compound as the polycondensation catalyst, the lower limit is usually 0.1 ppm or more, preferably 0.5 ppm or more, more preferably 1 ppm or more, as the amount of metal relative to the produced aliphatic polyester. The upper limit is usually 3000 ppm or less, preferably 1000 ppm or less, more preferably 250 ppm or less, and particularly preferably 130 ppm or less. If the amount of catalyst used is too large, it is not only economically disadvantageous, but the reason is not yet clear, but the carboxyl group terminal concentration in the resulting aliphatic polyester may increase, so the carboxyl group terminal amount In addition, the thermal stability and hydrolysis resistance of the aliphatic polyester may decrease due to an increase in the residual catalyst concentration. On the other hand, if the catalyst is too small, the polymerization activity is lowered, and accordingly, thermal decomposition of the aliphatic polyester is induced during the production of the aliphatic polyester, and it becomes difficult to obtain an aliphatic polyester having practically useful physical properties.

  The position of addition of the catalyst to the reaction system is not particularly limited as long as the catalyst is present in the polycondensation step, and may be added at the time of charging the raw material. If it coexists, the catalyst is deactivated and foreign matter is precipitated, which may impair the quality of the product. Therefore, it is preferably added after the esterification step. A particularly preferred form of addition of the catalyst is that which is continuously added to the liquid phase of the reaction liquid of the esterification reaction or polycondensation reaction after the end of the esterification reaction and before the end of the polycondensation reaction.

(3) Production Method of Aliphatic Polyester Preferred embodiments of the production method of aliphatic polyester according to the present invention using succinic acid as the aliphatic dicarboxylic acid and malic acid as the polyfunctional compound as raw materials are as follows. Although described with reference numerals attached thereto, the present invention is not limited to the illustrated form. Hereinafter, a diol component containing 1,4-butanediol is simply referred to as “1,4-butanediol”.

  FIG. 1 is a system diagram showing an embodiment of an esterification step in the present invention, and FIG. 2 is a system diagram showing an embodiment of a polycondensation step in the present invention.

  In FIG. 1, succinic acid and malic acid as raw materials are usually mixed with 1,4-butanediol (may be referred to as BG) in a raw material mixing tank (not shown), and from the raw material supply line (1). It is supplied to the esterification reaction tank (A) in the form of slurry or liquid. In addition, when a catalyst is added during the esterification reaction, the catalyst is supplied from the esterification reaction tank catalyst supply line (16) after being made into a solution of 1,4-butanediol in a catalyst adjustment tank (not shown). The

  Here, the lower limit of the molar ratio of 1,4-butanediol to the aliphatic dicarboxylic acid component supplied to the esterification reaction tank (A) is usually 0.6, preferably 0.8, particularly preferably 0. .9. The upper limit of this molar ratio is usually 1.6, preferably 1.3, particularly preferably 1.2. If this molar ratio is less than the above lower limit, the esterification reaction tends to be insufficient, and the polycondensation reaction, which is a reaction in the subsequent step, is difficult to proceed, making it difficult to obtain an aliphatic polyester having a high degree of polymerization. On the other hand, when the molar ratio is higher than the above upper limit, the decomposition amount of 1,4-butanediol and the aliphatic dicarboxylic acid component increases, which is not preferable.

The “molar ratio of 1,4-butanediol to the aliphatic dicarboxylic acid component supplied to the esterification reaction tank” in the present invention will be described below.
The 1,4-butanediol supplied to the esterification reaction tank (A) means 1,4-butanediol supplied as a slurry or liquid from the raw material supply line (1) and the esterification reaction tank (A). 1 refers to 1,4-butanediol supplied from a BG recirculation line (2) as shown in FIG. 1, and the aliphatic dicarboxylic acid component supplied to the esterification reaction tank (A) is a raw material It refers to an aliphatic dicarboxylic acid supplied as a slurry or liquid from the supply line (1). When 1,4-butanediol is supplied from the BG recirculation line (2), the 1,4-butanediol distilled and separated from the esterification reaction tank (A) is used as it is in order to keep the molar ratio within a preferable range. The BG supply line (3) can be connected to the BG recirculation line (2), and both can be mixed and then supplied to the esterification reaction tank (A).

  The lower limit of the esterification reaction temperature is usually 200 ° C or higher, preferably 210 ° C or higher, more preferably 215 ° C or higher, and the upper limit is usually 240 ° C or lower, preferably 235 ° C or lower, more preferably 233 ° C or lower. If the esterification reaction temperature is lower than the above lower limit, the esterification reaction rate becomes slow, requiring a long reaction time, and undesired reactions such as dehydration decomposition of 1,4-butanediol tend to occur. On the other hand, when the esterification reaction temperature exceeds the upper limit, 1,4-butanediol and aliphatic dicarboxylic acid components are decomposed more, and scattered substances increase in the reaction tank, which easily causes foreign matters. As a result, turbidity (haze) is likely to occur in the esterification reaction product. The esterification reaction temperature is preferably a constant temperature in order to stabilize the esterification rate. The constant temperature refers to a range of ± 5 ° C. of the normal set temperature, and preferably within a range of ± 2 ° C.

  The lower limit of the esterification reaction pressure is usually 50 kPa, preferably 60 kPa, more preferably 70 kPa, and the upper limit is usually 200 kPa or less, preferably 130 kPa, more preferably 110 kPa. When the esterification reaction pressure is lower than the above lower limit, the amount of scattered matter increases in the esterification reaction tank, haze of the esterification reaction product becomes high, and it is easy to cause an increase in foreign matters. Further, the distillation of 1,4-butanediol to the outside of the reaction system increases, and the polycondensation reaction rate tends to decrease. On the other hand, when the esterification reaction pressure is higher than the above upper limit, 1,4-butanediol is dehydrated and decomposed, and the polycondensation reaction rate is likely to decrease.

  The reaction atmosphere of the esterification reaction is usually an inert gas atmosphere such as nitrogen or argon. Moreover, reaction time is 1 hour or more normally, and an upper limit is 10 hours or less normally, Preferably it is 6 hours or less.

  The ratio of the terminal acid value to the total terminal group amount of the molten polymer in the esterification reaction tank (A) (R: hereinafter sometimes referred to as “terminal acid value ratio R”) has a lower limit of usually 0.40 or more, Particularly preferably, it is 0.45 or more, and the upper limit is usually 0.80 or less, particularly preferably 0.70 or less. When the terminal acid value rate R is lower than the above lower limit, the cyclization reaction at the hydroxyl terminal of the molten polymer is promoted, and THF tends to be easily produced as a by-product. In addition, since the polymerization reaction takes a reaction form mainly by transesterification, conditions of high temperature and high vacuum are required, and as a result, THF by-product and low-molecular-weight component volatilization are promoted.

  Here, as a factor affecting the terminal acid value rate R in the esterification reaction tank (A), the molar ratio of 1,4-butanediol to the aliphatic dicarboxylic acid component supplied to the esterification reaction tank (A), Examples include reaction temperature, reaction pressure, and residence time. By selecting the optimal reaction temperature, reaction pressure, and residence time for the molar ratio of 1,4-butanediol to the aliphatic dicarboxylic acid component supplied to the esterification reactor (A), the terminal acid value rate R Can be controlled within a preferable range. Among them, the method of adjusting the terminal acid value rate R by the residence time is the simplest.

  As the esterification reaction tank (A) used in the present invention, a known one can be used, and any type of tank such as a vertical stirring complete mixing tank, a vertical heat convection mixing tank, a tower type continuous reaction tank, etc. May be. Among them, a reaction tank having a stirrer is preferable. As a stirrer, in addition to a normal type including a power unit and a bearing, a shaft, and a stirring blade, a turbine stator type high-speed rotating stirrer, a disk mill type stirrer, a rotor mill type stirrer, and the like The type that rotates at a high speed can also be used. In the illustrated embodiment, the esterification reaction is carried out in one esterification reaction tank (A). However, as shown in the figure, a single tank or a plurality of tanks in which the same or different tanks are connected in series. It may be configured.

  There is no restriction | limiting also in the form of stirring in an esterification reaction tank (A), and the reaction liquid in an esterification reaction tank (A) is normally stirred from the upper part, lower part, side part, etc. of an esterification reaction tank (A). In addition to the stirring method, a part of the reaction solution can be taken out of the esterification reaction vessel (A) with piping or the like and stirred with a line mixer or the like to circulate the reaction solution to the reaction vessel. In addition, known types of stirring blades can be selected, and specific examples include propeller blades, screw blades, turbine blades, fan turbine blades, disk turbine blades, fiddler blades, full zone blades, Max blend blades, and the like.

  In the esterification reaction, the gas distilled from the esterification reaction tank (A) is separated into a high-boiling component and a low-boiling component in the rectification tower (C) via the distillation line (5). Usually, the main component of the high boiling component is 1,4-butanediol, and the main components of the low boiling component are water and tetrahydrofuran.

  The high boiling component separated in the rectification column (C) is extracted from the extraction line (6), passes through the pump (D), and partly from the BG recirculation line (2) to the esterification reaction tank ( It is circulated to A) and part is returned to the rectification column (C) from the circulation line (7). Further, the surplus is extracted outside from the extraction line (8). On the other hand, the light boiling components separated in the rectification column (C) are extracted from the gas extraction line (9), condensed in the condenser (G), and temporarily passed through the condensate line (10) to the tank (F). Can be stored. A part of the light boiling components collected in the tank (F) is returned to the rectification column (C) through the extraction line (11), the pump (E) and the circulation line (12), and the remainder is extracted. It is extracted outside through the line (13). The condenser (G) is connected to an exhaust device (not shown) via a vent line (14). The esterification reaction product generated in the esterification reaction tank (A) passes through the extraction pump (B) and the extraction line (4) of the esterification reaction product, and then passes through the first polycondensation reaction tank (a ).

  In the process shown in FIG. 1, the BG supply line (3) is connected to the BG recirculation line (2), but both may be independent. Moreover, the raw material supply line (1) may be connected to the liquid phase part of the esterification reaction tank (A). In addition, when a catalyst is added to the esterification reaction product before the polycondensation reaction, the catalyst is prepared to a predetermined concentration in a catalyst preparation tank (not shown) and then passed through the catalyst supply line (17) in FIG. 1 is supplied to the extraction line (4) for the esterification reaction product from the esterification reaction tank (A) shown in FIG.

In the present invention, in the esterification step, the esterification reaction product that is preferably esterified to an esterification rate of 80% or more is subjected to the next polycondensation reaction. Here, the esterification rate indicates the ratio of the esterified acid component to the total acid component in the esterification reaction product sample, and is represented by the following formula.
Esterification rate (%) = ((saponification value−acid value) / saponification value) × 100

  The esterification rate of the esterification reaction product is usually 80% or more, preferably 82% or more, more preferably 85% or more. When the esterification rate is lower than the lower limit, the reactivity of the polycondensation reaction in the subsequent step is deteriorated. Further, the amount of scattered matter during the polycondensation reaction increases and adheres to the wall surface and solidifies, and further, this scattered matter falls into the reaction material, causing deterioration of the haze (foreign matter generation) of the resulting aliphatic polyester. The upper limit of the esterification rate is preferably higher for the polycondensation reaction in the subsequent step, but is usually 99%.

The terminal carboxyl group concentration of the esterification reaction product is preferably 500 to 2500 equivalent / ton. The lower limit of the terminal carboxyl group concentration of the esterification reaction product is more preferably 800 equivalent / ton, particularly preferably 1000 equivalent / ton, and the upper limit is more preferably 2200 equivalent / ton, particularly preferably 2000 equivalent / ton. When the terminal carboxyl group concentration of the esterification reaction product is lower than the lower limit, 1,4-butanediol is decomposed more. Further, the amount of scattered matter during the polycondensation reaction increases and adheres to the wall surface and solidifies, and further, this scattered matter falls into the reaction material, causing deterioration of the haze (foreign matter generation) of the resulting aliphatic polyester.
The terminal carboxyl group concentration of the esterification reaction product is determined by the method described in the Examples section described later.

  The esterification reaction is carried out continuously with the molar ratio of aliphatic dicarboxylic acid component to 1,4-butanediol, reaction temperature, reaction pressure and esterification rate within the above ranges, and the esterification reaction product is continuously polycondensed. By using the reaction, a high-quality aliphatic polyester having a low haze and a small amount of foreign matters can be efficiently obtained.

  The esterification reaction product extracted from the esterification reaction vessel (A) through the extraction line (4) of the esterification reaction product and passed through the filter (g) is the first polycondensation reaction vessel (a ) And polycondensed under reduced pressure to form a polyester low polymer. The polyester low polymer polycondensed in the first polycondensation reaction tank (a) is then passed through an extraction gear pump (d), an extraction line (24) as an outlet channel, and a filter (h). It supplies to a polycondensation reaction tank (b). In the second polycondensation reaction tank (b), the polycondensation reaction is usually further advanced at a lower pressure than in the first polycondensation reaction tank (a). The obtained polycondensate is supplied to the third polycondensation reaction tank (c) through the extraction gear pump (e), the extraction line (25) serving as the outlet channel, and the filter (i). The polycondensation reaction proceeds.

  There is no restriction | limiting in particular in the type of the polycondensation reaction tank used for this invention, For example, a vertical stirring polymerization tank, a horizontal stirring polymerization tank, a thin film evaporation type polymerization tank etc. can be mentioned. The polycondensation reaction tank may be a single tank or a plurality of tank structures in which a plurality of tanks of the same or different types are connected in series as shown in the figure. Perform polycondensation reaction.

  Of the multiple polycondensation reaction tanks, the latter polycondensation reaction tank in which the viscosity of the reaction solution rises is a horizontal agitation that has a thin film evaporation function with excellent interface renewability, plug flow properties, and self-cleaning properties. It is preferable to select a polymerization machine. For example, in this embodiment, the third polycondensation reaction vessel (c) is preferably a horizontal reaction vessel comprising a plurality of stirring blade blocks and equipped with a biaxial self-cleaning type stirring blade.

The polycondensation reaction is usually performed under reduced pressure.
In the present invention, when the pressure of the polycondensation reaction tank having the lowest pressure among the reaction pressures in the polycondensation step is Pmin, Pmin ≧ 0.20 kPa. The method of producing using the ultra-high vacuum polycondensation equipment by lowering the pressure Pmin of the lowest pressure polycondensation reaction tank is a preferable mode from the viewpoint of improving the polycondensation reaction rate, but is extremely expensive equipment. In addition to increasing the volatility of low molecular weight components into the vacuum system and causing clogging in the condenser, it is difficult to operate stably for a long period of time. Since control of a ratio tends to be difficult, it is not preferable.
Pmin is preferably 0.25 kPa or more, more preferably 0.30 kPa or more. The upper limit of the pressure Pmin of the lowest pressure polycondensation reaction tank is usually 1.4 kPa or less, preferably 1.0 kPa or less. When the pressure during the polycondensation reaction is too high, the polycondensation time becomes long, and accordingly, the molecular weight is lowered and the color is caused by thermal decomposition of the polyester, which tends to make it difficult to produce a polyester having practically sufficient characteristics.

  In the polycondensation step, the polycondensation reaction tank having the lowest pressure is usually the last stage polycondensation reaction tank (the third polycondensation reaction tank (C) in FIG. 2).

  Also in other polycondensation reaction tanks, the lower limit of the reaction pressure is usually 0.35 kPa or more, preferably 0.45 kPa or more, more preferably 0.60 kPa or more, and the upper limit is usually 1.4 kPa or less, preferably 1. 0 kPa or less. As mentioned above, if the pressure during the polycondensation reaction is too high, the polycondensation time will be prolonged, resulting in a decrease in molecular weight and coloration due to thermal decomposition of the polyester, making it difficult to produce a polyester having practically sufficient characteristics. Tend to be. On the other hand, if the reaction pressure is too low, it will be difficult for long-term stable operation, such as requiring expensive capital investment, increasing the volatilization amount of low molecular weight components to the vacuum system, and causing clogging in the condenser. At the same time, it tends to be difficult to control the ratio of the terminal acid value to the total terminal group amount.

  Moreover, in this invention, when the temperature of the polycondensation reaction tank with the highest temperature is Tmax among the reaction temperatures in the polycondensation step, it is preferable that Tmax ≦ 260 ° C.

In the polycondensation step, the polycondensation reaction tank having the highest temperature is usually the final stage polycondensation reaction tank, but the polycondensation reaction rate is increased to produce a polyester having a high degree of polymerization in a short time. It is preferable that all the polycondensation reaction tanks have almost the same reaction temperature because the stirring power required for producing the polyester by lowering the melt viscosity can be reduced.
If the temperature Tmax of the polycondensation reaction tank having the highest temperature is too high, the thermal decomposition of the aliphatic polyester during the production is likely to occur, and the terminal acid in each reaction tank in the production of the aliphatic polyester having a high degree of polymerization or the polycondensation process. It tends to be difficult to control the valence R. Tmax is more preferably less than 250 ° C, still more preferably less than 245 ° C, and the lower limit is usually 220 ° C or more. If this temperature is too low, the polycondensation reaction rate is slow, and not only does it take a long time to produce a polyester with a high degree of polymerization, but also a high power stirrer is required, which is economically disadvantageous.

Also in other polycondensation reaction tanks, for the same reason as described above, the polycondensation reaction temperature is less than 250 ° C, particularly less than 245 ° C, and preferably 220 ° C or more.
The reaction atmosphere of the polycondensation reaction is usually an inert gas atmosphere such as nitrogen or argon.

  The lower limit of the polycondensation reaction time is usually 1 hour or longer, and the upper limit is usually 15 hours or shorter, preferably 10 hours or shorter, more preferably 8 hours or shorter. If the polycondensation reaction time is too short, the reaction is insufficient and it is difficult to obtain an aliphatic polyester having a high degree of polymerization, and the mechanical properties of the molded product tend to be inferior. On the other hand, if the polycondensation reaction time is too long, the molecular weight drop due to thermal decomposition of the aliphatic polyester becomes remarkable, and not only the mechanical properties of the molded product tend to be inferior, but also the carboxyl which adversely affects the durability of the aliphatic polyester. The amount of terminal groups increases due to thermal decomposition, and it tends to be difficult to control the terminal acid value rate R in each polycondensation reaction tank in the polycondensation step.

  In the present invention, the ratio of the terminal acid value to the total terminal group amount of the molten polymer in the polycondensation reaction tank, that is, the terminal acid value ratio R is usually 0.40 or more, preferably 0.45 or more, and the upper limit. Is 0.80 or less, preferably 0.70 or less. When the terminal acid value rate R is lower than the above lower limit, it is necessary to proceed the polymerization mainly by transesterification. Therefore, it is necessary to set the reaction temperature high and the reaction pressure lower, which is caused by thermal decomposition of the aliphatic polyester. Byproducts of THF and volatilization of low molecular weight components are likely to occur, and it is necessary to make the vacuum apparatus large, which is economically disadvantageous and tends to make long-term stable operation difficult. On the other hand, if the terminal acid value rate R is too higher than the above upper limit, it is necessary to distill off acid anhydrides such as succinic anhydride from the carboxyl terminal, which lowers the polymerization reaction rate and reduces succinic anhydride to the vacuum system. Since the evaporation of acid and the volatilization of low molecular weight components are remarkable, clogging with a condenser or the like is likely to occur, and this also tends to make long-term stable operation difficult.

  The aliphatic polyester that has undergone the polycondensation reaction in the third polycondensation reaction tank (c) passes through the extraction gear pump (f), the extraction line (26) that is the outlet channel, and the filter (j) to the die head ( k) is extracted in the form of a melted strand, cooled with water or the like, and then cut with a rotary cutter (l) to form polyester pellets.

  (21), (22), and (23) are vent lines of the first polycondensation reaction tank (a), the second polycondensation reaction tank (b), and the third polycondensation reaction tank (c), respectively.

  In FIG. 2, filters (g), (h), (i), and (j) installed before and after each of the polycondensation reaction tanks (a) to (c) are for removing foreign substances in the reaction product. It is not always necessary to install all of them, and they may be installed as appropriate in consideration of the effect of removing foreign substances and operational stability.

  The amount of THF produced as a by-product in the polycondensation step (“THF conversion rate” in the examples described later) is expressed in mol% relative to the amount of dicarboxylic acid component supplied as a raw material, and is usually 15 mol% or less, preferably 10 mol. % Or less, more preferably 5 mol% or less, still more preferably 3 mol% or less, particularly preferably 2 mol% or less. The amount of THF produced as a by-product in the polycondensation step is preferably as small as possible, and the load on the vacuum device is reduced. On the other hand, if the amount of THF produced as a by-product is large, the load on the vacuum apparatus is large and the target vacuum cannot be achieved, so that the reaction rate is significantly reduced, and a high molecular weight aliphatic polyester such as a predetermined viscosity is not obtained. I can't. Moreover, if it is going to achieve a high degree of vacuum, it is necessary to introduce an excessive vacuum device, which is industrially disadvantageous.

  In FIG. 2, the polycondensation reaction tanks (a) to (c) and the polycondensation reaction tank supply lines (18), (19) and (20) installed in front of the polycondensation reaction tanks (a) to (c), respectively. ) Is for controlling the terminal acid value ratio R, which is the ratio of the terminal acid value with respect to the total terminal group amount of the molten polymer at the outlet of each reaction tank, to a preferred range, and is appropriately determined depending on the ratio of the terminal acid value 1,4-butanediol can be added.

(4) Aliphatic polyester Melting, which is one of the melt indexes, is an index representing the viscosity of the aliphatic polyester obtained by the production method of the present invention (hereinafter sometimes referred to as “the aliphatic polyester of the present invention”). A flow volume (hereinafter referred to as “MVR” as appropriate) can be used. The MVR of the aliphatic polyester of the present invention is arbitrary as long as the effects of the present invention are not significantly impaired, but the lower limit of the value of the melt flow volume MVR per unit time measured at 190 ° C. and a load of 2.16 kg is usually 0. .1cm ^3/10 minutes or more, preferably 0.5 cm ^3/10 minutes or more, more preferably 1.0 cm ^3/10 minutes or more, particularly preferably at 1.5 cm ^3/10 minutes or more, the upper limit is usually 100 cm ³ / 10 min or less, preferably 60cm ^3/10 minutes or less, more preferably 25 cm ^3/10 minutes or less, more preferably 15cm ^3/10 minutes or less, particularly preferably 10 cm ^3/10 minutes or less, particularly preferably 6.0cm is ^3/10 minutes or less. If the MVR of the aliphatic polyester is too small, the melt tension becomes too high, the moldability becomes poor, or the viscosity becomes high and the gelation of the aliphatic polyester may be promoted. It is difficult to obtain sufficient mechanical strength when made into a product.
The MVR of the aliphatic polyester is measured by the method described in the Examples section below.

Further, the lower limit of the terminal carboxyl group concentration (equivalent / ton) of the aliphatic polyester of the present invention is preferably 5 or more, more preferably 7 or more, still more preferably 10 or more, and particularly preferably 13 The upper limit is preferably 50 or less, more preferably 45 or less, and still more preferably 40 or less. The lower the terminal carboxyl group concentration of the aliphatic polyester, the better the thermal stability and hydrolysis resistance, but if it is too low, the amount of catalyst or the polymerization temperature must be lowered, which leads to a decrease in the polycondensation reaction rate. The molecular weight does not increase at a practical speed. On the other hand, if the terminal carboxyl group concentration of the aliphatic polyester is too high, the thermal stability is poor and thermal decomposition increases during molding.
The terminal carboxyl group density | concentration of aliphatic polyester is calculated | required by the method described in the term of the below-mentioned Example.

  The lower limit of the color b value in the Hunter color coordinates of the aliphatic polyester pellets of the present invention is preferably −3.0 or more, more preferably −1.0 or more, and particularly preferably 0.0. The upper limit is preferably 3.0 or less, more preferably 2.5 or less, and particularly preferably 2.0 or less. If the color b value is too small, the molded product may be bluish and unfavorable, and if it is too large, the molded product may be yellowish and unfavorable.

The solution haze of the aliphatic polyester of the present invention is preferably 0.01 to 2.5%. Although the lower the lower limit of the solution haze, the more transparent product can be obtained, and it is usually 0.01% or more. The upper limit of the solution haze is more preferably 2.0% or less, still more preferably 1.5% or less, and particularly preferably 1.0% or less.
If the solution haze of the aliphatic polyester is too large, the molded product becomes turbid, and the amount of foreign matters increases, which is not preferable. Here, the solution haze refers to the turbidity at an optical path length of 10 mm of a solution having a sample concentration of 10% by mass using a mixed solution of phenol / tetrachloroethane = 3/2 (mass ratio) as a solvent, and is expressed in%.

  The aliphatic polyester of the present invention may be blended with an aromatic-aliphatic copolymer polyester, an aliphatic oxycarboxylic acid, or the like to form an aliphatic polyester composition. In addition, carbodiimide compounds used as necessary, fillers, plasticizers, and other biodegradable resins within a range that does not impair the effects of the present invention, such as polycaprolactone, polyamide, polyvinyl alcohol, cellulose ester, An aliphatic polyester composition may be prepared by blending starch, cellulose, paper, wood powder, chitin / chitosan, animal / plant material fine powder such as coconut shell powder, walnut shell powder, or a mixture thereof. Furthermore, additives such as heat stabilizers, plasticizers, lubricants, anti-blocking agents, nucleating agents, inorganic fillers, colorants, pigments, ultraviolet absorbers, light stabilizers, etc. are used for the purpose of adjusting the physical properties and processability of the molded products. Further, a modifier, a crosslinking agent, etc. may be included.

  The production method of the aliphatic polyester composition is not particularly limited, but is a method in which raw material chips of the blended aliphatic polyester are melt-mixed in the same extruder, a method in which each is melted in a separate extruder, and then mixed, a single screw extrusion And a method of mixing by kneading using a general kneader such as a machine, a twin screw extruder, a Banbury mixer, a roll mixer, a Brabender plastograph, a kneader blender, and the like. In addition, it is possible to obtain a molded body at the same time as preparing a composition by directly supplying each raw material chip to a molding machine.

  The aliphatic polyester of the present invention and the resin composition using the aliphatic polyester have practical physical properties such as thermal stability, tensile strength, and tensile elongation, and therefore, general-purpose plastic molding such as injection molding, hollow molding, and extrusion molding. Forming films, laminate films, sheets, plates, stretched sheets, monofilaments, multifilaments, non-woven fabrics, flat yarns, staples, crimped fibers, striped tapes, split yarns, composite fibers, blow bottles, foams, etc. It is available for goods.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to a following example at all unless the summary is exceeded. In addition, the measuring method of the physical property and evaluation item which were employ | adopted in the following examples is as follows.

[Concentration of terminal carboxyl group of esterification reaction product (AV): equivalent / ton]
A sample (0.3 g) was placed in 40 mL of benzyl alcohol, heated at 180 ° C. for 20 minutes, cooled for 10 minutes, and then titrated with a 0.1 N KOH / methanol solution, and the value obtained was expressed in equivalents / ton.

[Esterification rate:%]
It calculated from the acid value and the saponification value by the following calculation formula (1). The acid value was determined by placing 0.3 g of the esterification reaction product sample in 40 mL of benzyl alcohol, heating at 180 ° C. for 20 minutes, cooling for 10 minutes, and titrating with a 0.1N KOH / methanol solution. The saponification value was determined by hydrolyzing the oligomer with a 0.5N KOH / ethanol solution and titrating with 0.5N hydrochloric acid.
Esterification rate = ((saponification value−acid value) / saponification value) × 100 Formula (1)

[Polymer terminal carboxyl group concentration (AV): equivalent / ton]
After pulverizing the sample, it was dried at 140 ° C. for 15 minutes in a hot air dryer, and 0.1 g was accurately weighed from the sample cooled to room temperature in a desiccator, taken into a test tube, 3 ml of benzyl alcohol was added, The solution was dissolved at 195 ° C. for 3 minutes while blowing dry nitrogen gas, and then 5 ml of chloroform was gradually added and cooled to room temperature. One to two drops of phenol red indicator were added to this solution, and titrated with a 0.1N sodium hydroxide benzyl alcohol solution with stirring while blowing dry nitrogen gas, and the procedure was terminated when the color changed from yellow to red. Moreover, the same operation was implemented as a blank, without melt | dissolving a polyester resin sample, and the terminal carboxyl group amount (acid value) was computed by the following formula | equation (2).
Terminal carboxyl content (equivalent / ton) = (ab) × 0.1 × f / w Formula (2)
(Where a is the amount of 0.1N sodium hydroxide in benzyl alcohol solution required for titration (μl), b is the amount of 0.1N sodium hydroxide in benzyl alcohol solution required for titration with a blank. (Amount (μl), w is the amount (g) of polyester resin sample, and f is the titer of 0.1N sodium hydroxide in benzyl alcohol)
The titer f of a benzyl alcohol solution of 0.1N sodium hydroxide was determined by the following method. Collect 5 ml of methanol in a test tube, add 1-2 drops as an indicator of an ethanol solution of phenol red, Titrate with 0.4 ml of 1N sodium hydroxide in benzyl alcohol to the color change point, then add 0.2 ml of 0.1N aqueous hydrochloric acid solution with known titer as a standard solution, and add 0.1N hydroxide again. The solution was titrated with a sodium benzyl alcohol solution to the discoloration point (the above operation was performed under dry nitrogen gas blowing). The titer f was calculated by the following formula (3).
Titer f = titer of 0.1N hydrochloric acid aqueous solution × amount of 0.1N hydrochloric acid aqueous solution collected (μl) / titration of 0.1N sodium hydroxide in benzyl alcohol solution (μl) Formula (3)

[Ratio of terminal acid value to total terminal group amount R (terminal acid value ratio R)]
^{Using 1} H-NMR, the amount of terminal hydroxyl groups in the sample and the amount of terminal vinyl groups in the sample were quantified by the following method, and the sum of the terminal acid value (carboxyl group) concentration was added to the sample of each reaction vessel. The ratio of the terminal acid value to the total terminal group amount was calculated.

[End group concentration by ¹ H-NMR]
A solution in which 20 mg of a sample was dissolved in 0.6 ml of deuterated chloroform was used as a measurement sample, and the ¹ H-NMR spectrum was measured at room temperature using a Bruker BioSpin Avance 400 spectrometer and quantified. The flip angle is 45 degrees, the data capture time is 4 seconds, the waiting time is 6 seconds, and the number of integrations is 256. The exponential function of LB (Line Broadening) = 0.1 Hz was used for the window function, and Fourier transform processing was performed.
<Terminal hydroxyl group concentration>
The hydroxyl group present at the end of the aliphatic polyester (ie, the terminal hydroxyl group) is determined by the peak of the methylene proton on the carbon atom to which the terminal hydroxyl group appearing near 3.66 ppm is directly bonded using ¹ H-NMR. Quantified.
<Terminal vinyl group concentration>
The amount of vinyl groups (that is, terminal vinyl groups) present at the end of the aliphatic polyester is present at the end of the aliphatic polyester appearing near 5.15 ppm or near 5.78 ppm using ¹ H-NMR. Quantified by the proton peak on the carbon atom forming the double bond.

[THF conversion rate in the polycondensation step: mol%]
A 300 mL stainless steel cylinder was connected to the exhaust side of the vacuum pump installed in each reaction tank in the polycondensation step, and gas was collected. After cooling the cylinder with ice water for 30 minutes, add 20 mL of pure water degassed with N _{2 for} 15 minutes or more using a syringe and gently shake for 3 minutes to sufficiently dissolve THF gas in pure water. After recording the weight, quantitative analysis was performed by gas chromatography. As a method of quantitative analysis, a calibration curve is prepared in advance with an aqueous THF solution, the THF concentration in the stainless steel cylinder is obtained from the Area value at the time of GC measurement, and the weight value recorded previously is used to determine the THF concentration in the cylinder. The amount was calculated.
Next, the residence time in the SUS cylinder is obtained from the exhaust gas flow rate of the vacuum pump, the amount of THF generated per unit time (mol / hr) is calculated, and the THF conversion rate (mol%) is calculated from the following equation (4). lead.
THF conversion rate = THF generation amount (mol / hr) / dicarboxylic acid charge per unit time (mol / hr) × 100 Formula (4)

[Measurement of melt flow volume (MVR)]
MVR which is a melt flow volume was measured according to the method of JIS-K7210 using a melt indexer manufactured by Takara Industries. Specifically, MVR was measured by subjecting the aliphatic polyester dried at 80 ° C. for 12 hours to a melt indexer. The conditions for melt indexer, melt flow volume per unit of time measured by a load 2.16kg a ^(cm 3/10 min) was MVR at 190 ° C..

[Example 1]
<Preparation of polymerization catalyst>
Into a glass eggplant-shaped flask equipped with a stirrer, 100 parts by mass of magnesium acetate tetrahydrate was added, and 1500 parts by mass of absolute ethanol (purity 99% by mass or more) was further added. Furthermore, 65.3 parts by mass of ethyl acid phosphate (mixing mass ratio of monoester and diester was 45:55) was added and stirred at 23 ° C. After confirming that magnesium acetate was completely dissolved after 15 minutes, 122 parts by mass of tetra-n-butyl titanate was added. Stirring was further continued for 10 minutes to obtain a uniform mixed solution. This mixed solution was transferred to an eggplant-shaped flask and concentrated under reduced pressure by an evaporator in an oil bath at 60 ° C. After 1 hour, most of ethanol was distilled off to obtain a translucent viscous liquid. The temperature of the oil bath was further raised to 80 ° C., and further concentrated under a reduced pressure of 5 Torr to obtain a viscous liquid. This liquid catalyst was dissolved in 1,4-butanediol to prepare a catalyst solution so that the titanium atom content was 3.5% by mass.

<Method for producing aliphatic polyester>
The aliphatic polyester was produced in the following manner by the esterification step shown in FIG. 1 and the polycondensation step shown in FIG.
First, with respect to 1.00 mol of succinic acid containing 0.18% by mass of malic acid, 1.10 mol of 1,4-butanediol and malic acid were mixed in a total amount of 0.0028 mol. A 50 ° C. slurry was charged in advance from a slurry preparation tank (not shown) through a raw material supply line (1) with an aliphatic polyester low molecular weight substance (esterification reaction product) having an esterification rate of 99 mass% in a nitrogen atmosphere. The esterification reaction tank (A) having a stirrer was continuously fed so as to be 54.4 kg / h.

  The internal temperature of the esterification reaction tank (A) is 230 ° C., the pressure is 101 kPa, and the produced water, tetrahydrofuran and excess 1,4-butanediol are distilled from the distillation line (5), and a rectifying column ( In C), a high boiling component and a low boiling component were separated. A part of the high-boiling component at the bottom of the column after the system was stabilized was extracted to the outside through an extraction line (8) so that the liquid level of the rectification column (C) was constant. On the other hand, a low boiling component mainly composed of water and THF is extracted in the form of gas from the top of the column, condensed by a condenser (G), and an extraction line (13) so that the liquid level of the tank (F) becomes constant. More extracted outside. At the same time, the entire amount of the bottom component of the rectification column (C) at 100 ° C. (98 mass% or more is 1,4-butanediol) is supplied from the BG recirculation line (2) and supplied to the esterification reaction tank (A). The molar ratio of 1,4-butanediol to succinic acid was adjusted to 1.16. The supply amount was 1.4 kg / h.

  The esterification reaction product produced in the esterification reaction tank (A) is continuously extracted from the extraction line (4) of the esterification reaction product using the extraction pump (B), and the esterification reaction tank (A). The liquid level was controlled so that the average residence time of the internal liquid in terms of succinic acid unit was 4.3 hours. The esterification reaction product extracted from the extraction line (4) was continuously supplied to the first polycondensation reaction tank (a). After the system was stabilized, the esterification rate of the esterification reaction product collected at the outlet of the esterification reaction tank (A) was 88.8%, and the terminal carboxyl concentration was 1309 equivalent / ton.

  A catalyst solution prepared in advance by the above-described method was prepared by diluting a catalyst solution diluted with 1,4-butanediol so that the concentration as titanium atoms was 0.1% by mass in a catalyst preparation tank. Through 17), the esterification reaction product was continuously fed to the extraction line (4) at 2.2 kg / h (the catalyst was added to the liquid phase of the reaction solution). The supply was stable during the operation period.

  The liquid level was controlled so that the internal temperature of the first polycondensation reaction tank (a) was 240 ° C., the pressure was 2.67 kPa, and the residence time was 2 hours. An initial polycondensation reaction was carried out while extracting water, tetrahydrofuran and 1,4-butanediol from a vent line (21) connected to a condenser and a decompressor (not shown). The obtained polyester was continuously supplied to the second polycondensation reactor (b) via the extraction line (24) by the extraction gear pump (d).

  The internal temperature of the second polycondensation reaction tank (b) is 240 ° C., the pressure is 0.66 kPa, the liquid level is controlled so that the residence time is 2 hours, and it is connected to a condenser and a decompressor (not shown). The polycondensation reaction was further advanced while extracting water, tetrahydrofuran and 1,4-butanediol from the bent line (22). The obtained polyester was continuously supplied to the third polycondensation reactor (c) via the extraction line (25) by the extraction gear pump (e).

  The liquid level was controlled so that the internal temperature of the third polycondensation reaction tank (c) was 240 ° C., the pressure was 0.27 Pa, and the residence time was 2 hours, and it was connected to a condenser and a decompressor (not shown). While extracting water, tetrahydrofuran and 1,4-butanediol from the vent line (23), the polycondensation reaction was further advanced. The obtained polyester passes through the extraction line (26) by the extraction gear pump (f), and is further continuously extracted in a strand form from the die head (k), and is cut by a rotary cutter (l) and pelletized. It was.

As a result, the condenser in the polycondensation process could be stably operated for 7 consecutive days without clogging. The THF conversion rate in the polycondensation step was 1.9 mol%.
Table 1 shows the terminal acid value rate R of the molten polymer at each reactor outlet, the THF conversion rate by-produced in the polycondensation step, the MVR of the obtained aliphatic polyester, Pmin and Tmax in the polycondensation step. In addition, the residence time of each said reaction tank is the value calculated | required from the holdup amount of the actual liquid. The same applies to the following.

[Example 2]
An aliphatic polyester was obtained in the same manner as in Example 1 except that 1,4-butanediol was not supplied from the BG recirculation line (2) and the BG supply line (3). The condenser in the polycondensation process could be stably operated for 7 consecutive days without clogging. The THF conversion rate in the polycondensation step was 1.7 mol%.
Table 1 shows the measurement results.

[Example 3]
The amount of slurry supplied to the esterification reaction tank (A) was changed to 68.3 kg / h, the residence time of each reaction tank was 3.6 hours for the esterification reaction tank (A), and the first polycondensation reaction tank The liquid level was controlled so that (a) was 1.6 hours, the second polycondensation reaction tank (b) was 1.5 hours, and the third polycondensation reaction tank (c) was 1.5 hours. Without supplying 1,4-butanediol from the circulation line (2) and the BG supply line (3), the catalyst solution was continuously fed to the esterification reaction product extraction line (4) at 2.7 kg / h. An aliphatic polyester was obtained in the same manner as in Example 1 except that it was supplied. The condenser in the polycondensation process could be stably operated for 7 consecutive days without clogging. The THF conversion rate in the polycondensation step was 2.1 mol%.
Table 1 shows the measurement results.

[Example 4]
An aliphatic polyester was obtained in the same manner as in Example 1 except that the pressure in the third polycondensation reaction tank (c) was 0.40 kPa. The condenser in the polycondensation process could be stably operated for 7 consecutive days without clogging. The THF conversion rate in the polymerization process was 1.5 mol%.
Table 1 shows the measurement results.

[Comparative Example 1]
A slurry prepared by mixing 1.30 mol of 1,4-butanediol and malic acid in a proportion of 0.0028 mol with respect to 1.00 mol of succinic acid is supplied to an esterification reaction vessel, Of the bottom component of the rectifying column (C) at 100 ° C. from the BG recirculation line (2) so that the molar ratio of 1,4-butanediol to succinic acid fed to the saponification reactor is 1.50. A part was fed to the esterification reactor. The supply amount was 4.6 kg / h. Further, the aliphatic polyester was the same as in Example 1 except that the pressure in (b) of the second polycondensation reaction tank was 0.40 kPa and the pressure in the third polycondensation reaction tank (c) was 0.13 kPa. Got. On the fifth day from the start of continuous operation, the circulating flow rate of the condenser connected to the first polycondensation reaction tank (a) and the second polycondensation reaction tank (b) decreases, the pressure indication value becomes unstable, and the operation is stable. I did not. The THF conversion rate in the polycondensation step was as high as 5.2 mol%.
Table 1 shows the measurement results.

[Comparative Example 2]
The liquid level was controlled so that the average residence time in terms of succinic acid units in the esterification reaction tank (A) was 3 hours, and the pressure in the third polycondensation reaction tank (c) was 0.66 kPa. Produced an aliphatic polyester in the same manner as in Example 1. The condenser in the polycondensation process was not clogged and could be stably operated for 7 consecutive days. However, the decomposition reaction proceeded and a high molecular weight polymer could not be obtained. The THF conversion rate in the polycondensation step was as high as 7.2 mol%.
Table 1 shows the measurement results.

[Comparative Example 3]
The liquid level is controlled so that the residence time of the esterification reaction tank (A) is 3 hours, the pressure of (b) of the second polycondensation reaction tank is 0.40 kPa, and the third polycondensation reaction tank (c) An aliphatic polyester was obtained in the same manner as in Example 1 except that the pressure was 0.13 kPa. On the sixth day from the start of continuous operation, the circulation flow rate of the condenser connected to the first polycondensation reaction tank (a) and the second polycondensation reaction tank (b) decreases, the pressure indication value becomes unstable, and the operation is stable. I did not. The THF conversion rate in the polycondensation step was 3.8 mol%.
Table 1 shows the measurement results.

  According to the present invention, the temperature, pressure, residence time, aliphaticity in the esterification step, the polycondensation step, so that the end group quality of the molten polymer at the outlet of the esterification reaction vessel and the polycondensation reaction vessel becomes a specific ratio. By optimizing the conditions such as the molar ratio of 1,4-butanediol to the dicarboxylic acid component, the melt weight can be increased with an industrially advantageous and efficient production method without requiring excessive vacuum equipment. An aliphatic polyester having a high condensation reaction rate and a reduced amount of THF by-product and low-molecular-weight components in the polycondensation step can be produced.

1 Raw Material Supply Line 2 BG Recirculation Line 3 BG Supply Line 4 Esterification Reaction Product Extraction Line 5 Distillation Line 6 Extraction Line 7 Circulation Line 8 Extraction Line 9 Gas Extraction Line 10 Condensate Line 11 Extraction Line 12 Circulation line 13 Extraction line 14 Vent line 15 Supply line 16 Supply line 17 Catalyst supply line 18, 19, 20 BG supply line 21, 22, 23 Vent line 24, 25, 26 Polycondensation reaction product extraction line A Esterification Reaction tank B Extraction pump C Rectification tower D, E Pump F Tank G Capacitor a First polycondensation reaction tank b Second polycondensation reaction tank c Third polycondensation reaction tank d, e, f Gear pump for extraction g, h, i, j Filter k Die head l Rotary cutter

Claims (6)

Using an aliphatic dicarboxylic acid component and 1,4-butanediol as raw materials, an esterification step in which an esterification reaction product is obtained by carrying out an esterification reaction in an esterification reaction tank, In a method for producing an aliphatic polyester having a polycondensation step for obtaining an aliphatic polyester by continuously performing a melt polycondensation reaction in a condensation reaction tank,
The ratio (R) of the terminal acid number to the total terminal group amount of the molten polymer in the esterification reaction tank and the polycondensation reaction tank is controlled to 0.40 or more and 0.80 or less, and the reaction pressure in the polycondensation step Among them, when the pressure of the polycondensation reaction tank having the lowest pressure is Pmin, Pmin ≧ 0.20 kPa is satisfied.   The aliphatic polyester according to claim 1, wherein a molar ratio of 1,4-butanediol to an aliphatic dicarboxylic acid component supplied to the esterification reaction tank is 0.8 or more and 1.3 or less. Production method.   The method for producing an aliphatic polyester according to claim 1, wherein the Pmin is Pmin ≧ 0.25 kPa.   4. The method according to claim 1, wherein Tmax ≦ 260 ° C., where Tmax is the temperature of the polycondensation reaction tank having the highest temperature among the reaction temperatures in the polycondensation step. 5. A method for producing an aliphatic polyester.   The method for producing an aliphatic polyester according to any one of claims 1 to 4, wherein 1,4-butanediol is added to at least one polycondensation reaction tank in the polycondensation step.   The method for producing an aliphatic polyester according to any one of claims 1 to 5, wherein a titanium compound is used as a polycondensation reaction catalyst in the polycondensation step.

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